New Product Case Study Part 3 A

part 3 a of 7 part Case Study

1 Product development

Luxury brand Case Study

2

Notes

3

November 2012

Max Ruckman, Black & Decker HHI

Bill O’Connor, Source, Inc.

Andy Schechterman, MS, PHD

Michael Eckersley, MFA, PHD

Bruce Eckman

FRCH

Luxury Brand

Business

Development

Case Study Part 3 A

www.maxruckman.com

4

Phase iii

5

Phase iii

6

Phase iii

manufacturing input

7

Phase iii

supplier input

8

Phase iii

9

Phase iii

10

Phase iii

layout drawings

11

Phase iii

12

Phase iii

approved industrial design model

13

Phase iii

14

Phase iii

patent review

15

patent attorneys have presented an opinion of non-infringement

16

patent disclosure

Patent review

provisional patents will be converted to patents

model numbers will be provided for top and lower level components

17

manufacturing and documentation teams will resolve issues

new SKU’s and EASE label numbers will be applied to the product

Documentation

Phase iii

18

Phase iii

product definition

19

Next steps

20

Manufacturing plan

21

22 Situational analysis


tuscan villa collection


Craftsman

collection


French chateau collection


general specifications


Packaging Specifications

29

IRR

Financial summary

30

$394,000 Initial tooling & equipment

Financial summary

31

$70,000

program expenses

Financial summary

32 Financial summary

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39 Part 3A steps

create a business unit that will offer an

upscale brand of unique door hardware,

with an emphasis on architecturally

styled products for the home market

40 objective

craftsmen

41 scope

future plans to add approximately 4 new families

product families

french chateau

tuscan villa

42 scope

a complete breath of product will be developed for each family

mortise box

tubular deadbolt

knob lever

hinges

pocket door door knocker

door bell

surface bolt

address numbers

marketing

packaging documentation

quality sourcing manufacturing

logistics

finance

process/product development

supply chain distribution

customer service

43 Team members

44 Program organization flow chart

program will be released in (2) phases

preliminary manufacturing plan will only address timing of phase (1)

final manufacturing plan will encompass both launch phases

45 Preliminary schedule

Manufacturing Preliminary Schedule 290 days 03/25/03 05/03/04

Preliminary Sourcing Plan 25 days 03/25/03 04/28/03

Preliminary Manufacturing Plan 25 days 03/25/03 04/28/03

Design for Manufacturability 20 days 04/29/03 05/26/03

Make v . Buy Analysis 15 days 05/27/03 06/16/03

Finalized Unit Cost Analysis 15 days 06/17/03 07/07/03

Final Sourcing Strategy 10 days 07/08/03 07/21103

Finishing Process Development 60 days 07/08/03 09/29/03

Manufacturing Feasibility Analysis 10 days 05/27/03 06/09/03

Manufacturing Site Selection 5 days 06/10/03 06/16/03

Material Management Plan 20 days 06/17/03 07/14/03

Order Management Plan 20 days 07/15/03 08/11/03

Identify Manufacturing Process Equipment 20 days 07/15/03 08/11/03

Manufacturing Capability Analysis 15 days 07/15/03 08/04/03

Manufacturing Capacity Analysis 15 days 07/15/03 08/04/03

Operation & Assembly Strategy- Line 20 days 08/05/03 09/01/03

Quality Strategy 25 days 08/05/03 09/08/03

Distribution Strategy 15 days 08/12/03 09/01/03

Final Manufacturing Plan 5 days 09/09/03 09/15/03

Process FMEA Development 55 days 09/16/03 12/01/03

CAR & Expense Development 30 days 07/08/03 08/18/03

Tooling & Equipment Orders (Long Lead) 70 days 08/19/03 11/24/03

First Article and Other PQP Development 40 days 10/21/03 12/15/03

Order Launch Volume & Safety Stock 50 days 12/02/03 02/09/04

Production Line Development & Set-Up 80 days 08/19/03 12/08/03

Control Plan Development & TQC 35 days 12/02/03 01/19/04

Install & Sign-Off Equipment 20 days 12/09/03 01105/04

Finishing Process Transfer to Supplier 40 days 11/04/03 12/29/03

Documentation & SKU Activation 55 days 11/04/03 01/19/04

Logistics Plan 20 days 09/02/03 09/29/03

Service Parts Plan 10 days 09/30/03 10/13/03

Product Returns Plan 10 days 10/14/03 16)27/03

Pilot Build I Product Display 35 days 02/10/04 03/29/04

Ordering Available 5 days 03/30/04 04/05/04

Bulk I Ship Production 20 days 04/06/04 05/03/04

46 Manufacturing preliminary schedule

47 Schedule proposal

important: availability of design and engineering documents will dictate movement of the schedule

design completion engineering completion

contingency timing for extensive tooling modifications

re-submittal of first article

complete PQP and six sigma plan

design change

manufacturing schedule relies on supplier design

reviews and release of finalized drawings to support

the tooling and equipment build


a complete (phase 1) packet of pre-released, quote quality drawings must be available by 5/21/03

the (2) sub categories will launch in succession and

require the following lead times


long lead = 14wks (includes stamping, investment casting & finish development)

short lead = 8 wks (includes cold heading, sand casting and screw machine)

Critical Path-Manufacturing Pre-Schedule 290 days 03/25/03 05/03/04

Preliminary Sourcing (Cost/Supplier) Plan 25 days 03/25/03 04/28/03

Preliminary Manufacturing Plan 25 days 03/25/03 04/28/03

Design for Manufacturability 20 days 04/29/03 05/26/03

Make vs. Buy Analysis 15 days 05/27/03 06/16/03

Finalized Unit Cost Analysis (Eng.) 15 days 06/17/03 07/07/03

Final Sourcing Strategy 10 days 07/08/03 . 07/21103

CAR & Expense Development 30 days 07/08/03 08/18/03

Tooling & Equipment Orders (Long Lead) 70 days 08/19/03 01/24/03

First Article and Other PQP Development 40 days 10/21/03 02/15/03

Order Launch Volume & Safety Stock 50 days 12/02/03 02/09/04

Pilot Build I Product Dis '!Y

Ordering Available

35 days 02/10/00

03/30/04

03/29/04

04/05/04 5 days

Bulk i Ship Production 20 days 04/06/04 05/03/04

long lead items (14 wks) require approved drawings by 8/19/03

short lead items (8 wks) require approved drawings by 10/01/03

50 Critical path

note: the accessories will be categorized with a short lead tooling requirements

Launch Product Style Total Forecast

Phase 1 units Year 1 Year 2 Year 3 Year 4 Year 5

1 Handlesets 2,400 6,000 8,400 10,920 14,280

Sub-Total 2,400 6,000 8,400 10,920 14,280

2 Knob - Passage 1,800 3,600 6,300 8,190 10,710

3 Knob - Privacy 900 1,800 3,150 4,095 5,355

4 Knob - Inactive 300 750 1,050 1,365 1,785

Sub-Total 3,000 6,150 10,500 13,650 17,850

5 Lever - Passage 5,220 10,440 18,270 23,751 31,059

6 Lever - Privacy 2,610 5,220 9,135 11,876 15,530

7 Lever - Inactive 870 2,175 3,045 3,959 5,177

Sub-Total 8,700 17,835 30,450 39,585 51,765

8 Deadbolts 7,500 18,750 26,250 34,125 44,625

Sub-Total 7,500 18,750 26,250 34,125 44,625

9 Door Knockers 900 1,800 3,150 4,095 5,355

10 Door Bells 1,200 2,400 4,200 5,460 7,140

11 Address numbers 900 2,250 3,150 4,095 5,355

12 Surface bolts 600 1,200 2,100 2,730 3,570

13 Pocket Door Mortise 600 1,200 2,100 2,730 3,570

14 Hinges 6,000 13,000 8,400 10,920 14,280

Accessories Sub-Total 10,200 21,850 23,100 30,030 39,270

TOTAL 31,800 70,585 98,700 128,310 167,790

Year Over Year Growth 100% 122% 40% 30% 3l%

sales, volume and cost may not represent updates recently provided for the capital appropriation request model

the model accurately represents the team's estimates moving forward

51 Total sales volume (estimates)

52 Detailed volume projection & scope

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French · Craftsman Tuscany

Handleset - Tubular $ 210.00 Handleset - Tubular $ 190.00 Handleset- Tubular $ 190.. 00

Handleset ., Mortise $ 230.00 Handleset - Mortise $ 210.00 Handleset- Mortise $ 210..00

Deadbolts $ 65.00 Deadbolts $ 60. .00 Deadbolts $ 60. .00

Interior Knobs $ 83.00 Interior Knobs $ 75.00 Interior Knobs $ 75.00

Interior L.evers $ 83.00 Interior Levers $ 75.00 Interior Levers $ 75.00

Hinges $ 25.00 Hinges $ 20.00 Hinges $ 20.00

Pocket Door Locks $ 50.00 Pocket Door Locks $ 45.00 Pocket Door Locks $ 45.00

Door Knockers $ 40.00 Door Knockers $ 36.00 Door Knockers $ 36.00

Door Bells $ 22.00 Door Bells $ 21.00 Door Bells $ 21.00

House Numbers $ 19.. 00 House Numbers $ 18.00 House Numbers $ 18. 00

Surface Bolts $ 19.00 Surface Bolts $ 18.00 Surface Bolts $ 18.00

56 Target cost

57 Unit cost analysis

primary assumptions for standard cost

58 Unit cost analysis

59 Opportunity analysis

60 Component plan

61 Component plan

co

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62 Component process flow

63 Component process flow

64 Development requirements

note: a more discipline PQP process may be required to accommodate the casting requirements of this program

sourcing plan includes

a tracking sheet will be used for detail and volume requirements

sourcing will manage information relating to supplier selection,

cost, material, tooling, first article, complete PQP and lead-time

new collection systems will be reviewed in the final plan

65 Component tracking update

provides

insight into

the primary

components

required for

the launch

66 Component information

note: components are being reviewed and designed to accommodate customer ordering and manufacturing

product combines the deadbolt and standard

latch into (1) mechanism


mo

rt

ise

will not be manufactured within BDHHI because

the "engine" requires a recognized name

current schedule restraint does not lend itself to in-

house engineering and manufacture

consists of a knob/lever chassis with spring

housing, separate deadbolt and standard

latch component


TU

BU

LA

R

requires (3)cylinders for door thicknesses

and (2) key styles for Schlage and Kwikset


CY

LIN

DE

R

(6) types of cylinders to support the program

determine whether our manufacturing facilities

will need to pin cylinders

mortise cylinders will be purchased & pinned to order

chassis will be built into the escutcheon and

utilize (2) springs to support knobs and levers


CH

AS

SIS

product will be non-handed

product will be built upon order request

71 Risk factors

/

72 Risk factors

/

73 Risk factors

74 Risk factors

75 standardization

handle assembly

76 standardization

cylinder

77 standardization

latch

78 standardization

strike & front

79 standardization

screw packs

80 standardization

materials

81 Component testing

the new layout will support year 1 volumes with 1 shift, 1-2 additional shifts

can be added if necessary

84 Initial finish capability review

all finishes will be developed and applied at the Baldwin facility

capacity/capability analysis determined a new production line is

needed

a new plating line will be required to provide development and

production of oxide finishes

space allocation has been assigned

for the restructuring layout and is

under development


89 New in-house finish capability

bronze (silicon & white)

90 New in-house finish capability

tuscan villa (example)

Brass

91 finish capability

zinc

Steel

92 Cast and finish processing (supply chain)

93 Cast and finish processing (supply chain)

industrial capability does not exist; therefore the team is working under

(2) assumptions:

PROCESS SUPPUER LOCATION

SAND CAST Franklin Bronze Pennsylvania

INVESTMENT CAST Franklin Bronze Pennsylvania

DIE CAST

Eversafety

China

STAMPING Eversafety China

POWDER METAL Eversafety China

FINISH (Patina) Baldwin Pennsylvania

MORTISE BOX Pathline China

LATCHES Pathline China

CYUNDERS Pathline China

MACHINE CASTING Franklin Bronze Pennsylvania

PACKAGING Stephen Gould Pennsylvania

SUPPLY BASE PROFILE

94 Preferred supplier & development list

95 Finish tracking

96 Finish tracking

note: the previous component list identifies the finish for each component

note: this is a representative sample of a finish tracking sheet

product development will ensure that this format is refined

*sample swatches will be developed and utilized for process control and development

97 Finish tracking

volume projection 2004-2008 (12 month)

program is (2) phases

volume projection

identifies this objective

Italian Tuscany I Craftsman I French Country Collection

Launch Product Style Combined Forecast Average

Phase 1 Year 1 Year 2 Year 3 Year 4 Year 5 Cost

; Units $ Handlesets 2,400 6,000 8,400 1Q,920 14,280 $ 160.00

Sub-Total 2,400 6,000 8,400 10,920 14,280

Knob - Passage 1,800 3,600 6,300 8,190 10,710 $ 40.00

Knob - Privacy 900 1,800 3,150 4,095 5,355 $ 40.00

Knob - Inactive 300 750 1,050 1,365 1,785 $ 40.00

Sub-Total 3,000 6,150 10,500 13,650 17,850

Lever - Passage 5,220 10,440 18,270 23,751 31,059 $ 40.00

Lever - Privacy 2,610 5,220 9,135 11,876 15,530 $ 40.00

Lever - Inactive 870 2,175 3,045 3;959 5,177 $ 40.00

Sub-Total 8,700 17,835 30,450 39. 85 51,765

Deadbolts 7,500 18,750 26,250 34,125 44,625 $ 24.00

Sub-Total 7,500 18,750 26,250 34,125 44,625

Door Knockers 900 1,800 3.150 4,095 5,355 $ 27.00

Door Bells 1,200 2,400 4,200 5,460 7,140 $ 25.00

Address numbers 900 2,250 3,150 4,095 5,355 $ 12.00

Surface bolts 600 1,200 2,100 2,730 3,570 $ 10.00

Pocket Door Mortise 600 1,200 2,100 2,730 3,570 $ 6.00

Hinges 6,000 13,000 8,400 10,920 14,280 $ 7.00

Accessories Sub-Total 10,200 . 21,850 23,100 30,030 39,270

TOTAL 31,800 70,585 98,700 128,310 167,790

Year Over Year Growth 100% 122% 40% 30% 31%

-

98 Initial capacity review

Phase 2 Product Style Total Forecast Average

Year 1 Year 2 Year 3 Year 4 Year 5 Cost

Units :$

1 Switch plates 540 1,350 1,890 2,457 3,213 $ 6.00 . 2 Door Stops 3,000 - 10,500 13,650 17,850 $ '6.00 3 18" Towel Bar 1,200 2,400 4,200 5,460 7,140 $ 20.00 4 . 24" Towel Bar 1,200 2,400 4,200 5,460 7,140 $ 22.00 5 Towel ring 640 1,600 2,240 2,912 3,808 $ /20.00 6 Toilet Paper Holder 1,200 2,400 4,200 5,460 7,140 $'-: 10.00 7 Cup Holder/Toothbrush 300 600 1,050 1,365 1,785 $ 20_00 8 Cabinet knobs and pulls 3,000 7,500 10,500 13,650 17,850 $ ,·6.00

TOTAL 11,080 18,250 38,780 50,414 65,926

Year Over Year Growth 100% 65% 112% 30% 31'1o

99 Phase 2

Italian Tuscany I Craftsman I French Country Collection - with Accessories Launch Style Combined Forecast Average

Phase 1& 2 Unit Yr.1 Unit Yr.2 Unit Yr.3 Unit Yr.4 . Unit Yr.5 Cost

Handleset 2,400 6,000 8,400 10,920 14,280 $ 160.00

Knob 3,000 6,150 10,500 13,650 17,850 $ 40.00

Lever 8,700 17,835 30,45.0 39,585 51,765 $ 40.00

Deadbolt 7,500 18,750 26,250 34,125 44,625 $ 24.00

Accessories 21,280 40,100 61,880 80,444 105,196 $ 14.07

Total Incremental Increase to Business 42,880 88,835 137.480 178,724 233,716

100 Key assumptions

101 Available capacity

YR.1 = 90/day

yR.2 = 195/day

YR.3 = 300/day

102 Initial capability review


additional mexico operations

2003' Standard Rates

Mexicali Technolock

Direct Labor 4.57 2.86

Burden 11.41 20.78

Overhead 16.4 0

TOTAL 32..38 23.64

* Mexicali· Operation

* Technolock Utilized Grade 1Handleset

105 Operating cost

106 Operating cost

107 Operating cost

there is a wide array of new

processes, materials and operations

108 Capability analysis

109 Cast & Finish process (supply chain) / swot analysis

option 1 supports the

development plan and

program timeline

Strength

One Supplier Responsible for Finishing

Quality, Lead-Time and Cost

Proven Ability to Process & Finish

Low Volume, Attention to Detail

Small Foundries, Competitive Cost

Willingness to Obtain Priority Customer

Weakness

Capital investment for Materials and Staff

Supplier Cost- Overhead

Mexicali Assembly and Pack-Out

Supplier Available Quality Systems

Opportunity

Supplier Quality System Development

Product Consistency- One Supplier

Learning Curve in Mexicali

Threat

Supplier Available Quality System

Supplier Stability - Small Foundries

AcceleratedProcess Development

SCENARIO #1

OPERATION

Sand

Casting

Investment

Casting

Casting Supplier #l Supplier #1

Machining Supplier #1 Supplier #1

Finishing Supplier #1 Supplier #2

·.

Assetnbiy Mexicali Mexicali

Packout Mexicali Mexicali

110 Swot analysis

assumption #1 short term

assumption #2 long term SCENARI0#2

OPERATION Sand Costing Investment Casting

Casting Supplier#! Supplier#!

Machining Mexicali Mexicali

Finishing Mexicali Mexicali

Assembly Mexieali Mexicali

Packout Mexieali Mexicali

Strength

Mexicali Responsible for Quality, Lead-time, Cost

Mexicali Absorption Opportunity

Internal Control Over Finished Goods

Reduced WTP

Supply Chain Simplification

Weakness

New Finish Development Processes

Capital Investment

Resource Availability and Commitment

High Labor, Burden & Overhead Rates

Commitment to Schedule

Opportunity

Product Control and New Process Development

Product Consistency - One Supplier

Lead-Time Reduction

Threats

Business Support and Directive

Maintaining Launch Schedule

111 Swot analysis

112 Cylinder pinning


customers require a keyed handleset and deadbolt

product will be keyed alike

door thickness will impact cylinder length requirements

utilizes a 5-pin cylinder providing approximately 4,000 key cut options


OPTION 1


OPTION 2

cylinder material flow process


OPTION 3

117 Sourcing plan

principals have been adopted to select highly capable vendors

118 Supply base profile

Cast supplier (detail sand & investment)

119

Risk factors

MAKE

vs.

BUY

YR 1QTY

YR .2QTY

1

2

3

SAND CAST Buy 5,400 10,800 Franklin Bronze Bronze Craft Birmingham

Bronze

Investment Cast Buy 3,400 6,700 Franklin Bronze Aristocast Impro Industries

Die Cast

Square Spindle -13/8 Buy 24,840 49,680 Star Die B&C TBD

Square Spindle Extension - 13/4 Buy 8,694 17,388 Star Die B&C TBD

Square Spindle Extension- 2 1/4 Buy 3,726 7,452 Star Die B&C TBD

Square Spindle, Mortise ?? Buy 960 1,920 Star Die B&C TBD

Stamping .,_

Cylinder Cap Make 10,860 21,720 Denison Precision TBD

Torque Mortise Buy 960 1,920 Precision ..TBD TBD

Spring Housing Buy 24,840 49,680 Precision TBI) TBD

Mechanis111 Box Buy 2,880 5,760 Precision TBD TBD

Retaining Ring/Clip Buy 34,740 69.480 PPM TBD TBD

Washer Buy 53,040 106,080 Precision TBD TBD

Front Make 19,252 38,504 Denison Precision TBD

Strike Make 19,252 38,504 Denison Precision TBD

Powder Metal

Pinion, HS Buy 1,440 2,880 TBD TBD TBD

Rock, HS Buy 1,440 2,880 TBD TBD TBD

Finish (Patina, Pewter, Weathered

Supplier Vertically integrated Buy Franklin Bronze Bronze Craft Birmingham

Bronze

Supplier- Finish Only Buy Quaker Palm Springs Plat! Bronze\UCJY

OEM Components ..

Mortise Box Buy 1,200 2,400 AccUNte Baldwin

Cylinder I Key Buy - - Ilco GMS TBD

Latches Buy 9,000 17,000 Tong Lung Franklin Brass TBD

Machine Casting Buy 8,800 17,500

Franklin Bronze Bronze Craft Birmingham

Bronze

Make vs. Buy list

120

initial make vs buy analysis was generated

based on the following principals

Make vs. buy

121

low volume, high mix

no sand and investment cast operation

new finish requirements and development

Make vs. buy

122

Make vs. buy

123

NEW COMPONENTS

MAKE BUY YR 1 QTY YR 2 QTY #1 SUPPLIER #2- SUPPLIER

SAND CAST Buy

48,000

96,000

Franklin Bronze

Trimco

INVESTMENT CAST Buy

96,000

192,000

Franklin Bronze

Trimco

DIE CAST

Square Spindle Buy

15,000

30,000 New Forge

B&C

STAMPING

Spring Retainer, Knob Buy 7,800 15,600 Synergy Eversafety

Lever Stop Buy 18,060 36,120 Synergy Eversafety

Bushing, Flat Buy 26,820 53,640 Synergy Eversafety

Bridge Buy 23,460 46,920 Synergy Eversafety

Bushing, Bridge Buy 30,596 61,192 Synergy Eversafety

Bushing, Knob/Lever Buy 23,824 47,648 Synergy Eversafety

Spring, Handleset Knob Buy 576 1,152 Synergy Eversafety

Spring, Knob Buy 5,976 11,952 Synergy Eversafety

Spring, Lever Buy 17,100 34,200 Synergy Eversafety

Mounting Plate, DB Buy 8,460 16,920 Synergy Eversafety

Spring, DB Detent Buy 8,460 16,920 Synergy Eversafety

Cam, DB Detent Buy 8,460 16,920 Synergy Eversafety

Spindle, Handleset Buy 960 1,920 Synergy Eversafety

Spindle, Passage Buy

6,420 12,840 Synergy Eversafety

Spindle, Privacy 3,510 7,020 Synergy Eversafety

Retainer, Push Buy 33,360 66,720 Synergy Eversafety

Exterior Screw Post Buy 50,720 101,440 Synergy Eversafety

Interior Screw Post Buy 50,720 101,440 Synergy Eversafety

Bushing Retainer Buy 23,460 46,920 Synergy Eversafety

MACHINE CASTING Buy 144,000 288,000 Franklin Bronze Baldwin

Make vs. Buy component list

124

Cast component process flow

125

Development requirements

126

Sourcing plan includes:

Development requirements

127

Engineering analysis

128

Designs require

Engineering analysis

129

engineering will focus on eliminating

Assembly plan

130

Assembly plan

131

product team will review opportunities:

,.,

Assembly & pack - out

132

,.,

Assembly & pack - out

133

OPERATING RATES

Engineering sample lot plan

134

Bulk production plan

135

Engineering testing

136

Tool and equipment cost estimate

137

equipment count 13

Total cost

138

COST TOTALS

capital budget $742,650

program expense $155,000

total investment $897,650

tool count 120<

Logistics plan

139

Sku count detail

140

SKU breakdown

Total SKU's without

cylinders and

keying = 1,206

ORDER MANAGEMENT

Internal process supply chain

141

order management supply planning opertation distribution

ORDER MANAGEMENT

Internal process supply chain

142

Supply planning

143

Supply planning

144

guiding principles

Italian Tuscany I Craftsman I French Country Collection - with Accessories

Phase 1 UnitYr.1 Unit Yr.2 Unit Yr.3 Unit Yr.4 Unit Yr.5

Total $ 176,109 $ 384,089 $ 544,573 $ 707,945 $ 877,049

Proposed estimated inventory dollars

145

Operations management strategy

146

the following elements will be developed

to establish systems and procedures for

reliable and repeatable production

processes

distribution

147

distribution

148

distribution

149

RISK FACTORs

Quality plan

150

internal and external vendors

will use:

Quality plan

151

procedures include these elements to

be completed prior to product launch

Explicit Customer CTQ's Implicit Customer CTQ's Features to Meet Voice of Customer

Solid Feel Tubular/Mortise on a standard chassis Introduce Bronze Alloys

Architectural Style New Oxidized Finishes Eliminate Lever & Thumbpiece Wobble

Customer Service Packaging - Hold 15-20 1b Specification - Grade 2- 3 requirements

Functionality Utilize Current Thumbpiece Minimal Axial Play on Levers & Knobs

Size & Weight to Exceed Current Designs

Level 2 research conducted for resolution

Six sigma critical to quality

152

supplier part

certification

process first

article

inspection

Tool quality

153

established during the

development of engineering

drawings

Tool quality

154

new product validation

part qualification

process - combination

of tools listed

reviewed during

design review and

tooling development

capable within 1.0-1.33 cpk (approximately 4 sigma where applicable)

Tool quality

155

process capability analysis

supplier to display control of ctq dimensions

supplier to provide control

plan including inspection,

data collection points and key

process parameters

Tool quality

156

control plan

supplier to generate

final audit to include

elements discussed

during design

Tool quality

157

final audit plan

Manufacturing feasibility statement

158


159


160


161

critical areas must be closely

managed to meet the schedule

Plant requirements

162

space allocation

Plant requirements

163

short-term

Plant requirements

164

long-term

Plant requirements

165

test fixture

plan will

include

corporate &

manufacturing

resource

needs

Resource assessment

166

Service plan

167

Service parts

168

Warranty plan

169

CUSTOMER SERVICE

November 2012

Max Ruckman, Black & Decker HHI

Bill O’Connor, Source, Inc.

Andy Schechterman, MS, PHD

Michael Eckersley, MFA, PHD

Bruce Eckman

FRCH

Luxury Brand

Business

Development

Case Study Part 3 A

www.maxruckman.com

170

New Product Case Study Part 3 A

Business

Transcript of New Product Case Study Part 3 A